Method for manufacturing towels of low-twist yarns

ABSTRACT

The present invention discloses a method for manufacturing low-twist towels, wherein pure cotton yarns produced from long-staple cotton are used as terry warps to manufacture low-twist towel by the processes comprising warping, weaving and greige post treatment, and the terry warp has a yarn twist multiplier of 240-270. The method eliminates the step of removing water-soluble filaments during post treatment, thereby reducing post treatment costs, relieving the pressure on sewage treatment and attaining environmental friendly effects. The resulting products have standing loops and a fluffy and soft texture.

BACKGROUND OF THE INVENTION

The present invention relates to the production of textiles and more particularly pertains to a method for manufacturing towels.

In the current towel industry, the highly-absorbent and super soft products are mainly products of non-twist yarns. Products made of non-twist yarns attain high water absorbency and super soft texture, yet it is necessary to add additives to dissolve the PVA materials generated after processing, thereby causing water pollution, increasing difficulty in sewage treatment, and elevating the costs.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a method for manufacturing low-twist towels which have standing loops and are fluffy, soft in texture and environmental friendly.

To attain this, the present invention provides a method for manufacturing low-twist towels, wherein pure cotton yarns produced from long-staple cotton are used as terry warps to manufacture low-twist towel by the processes comprising warping, weaving and greige post treatment, and the terry warp has a yarn twist multiplier of 240-270.

Pure cotton yarns are produced from the long-staple cotton by the following processes:

Cotton opening and picking process: Raw long-staple cotton are opened and picked to produce cotton laps or cotton layers;

Cotton carding process: The processed cotton laps or cotton layers are combed to form card slivers;

Combing process: The card slivers are subject to fine combing;

Drawing process: 6-8 strands are blended together;

Roving process: The card slivers are drawn to be thinner by 5-12 times to produce rovings;

Spinning process: The rovings are drawn out and spinned into spun rovings;

Yarn winding process: The spun rovings are wound onto a bobbin to form a yarn.

The pure cotton yarn produced from the long-staple cotton has a yarn count of 64.8 tex and a twist number of 30 turns per 10 cm.

Warping process: Warping may be done by a sectional warping machine.

Sizing process: To provide the yarn with sufficient strength to ensure successful weaving, the present invention has a sizing rate which is 50% higher than that of conventional art.

Weaving process: Three-pick loop fabric is weaved by using a warp density of 56-60 reed and a weft density of 45 wefts per 2.54 cm, and a loom speed of 420 revolutions per minute.

The greige post treatment processes includes desizing, scouring, dyeing, softening and drying.

The scouring solution used for scouring has a sodium hydroxide concentration of 5±0.5 ml/L, a hydrogen peroxide stabilizer concentration of 0.7±0.05 ml/L, and a hydrogen peroxide concentration of 6.7±0.05 ml/L.

The dyeing process may utilize Ramazol environmental friendly dyeing chemicals produced by Dystar. After adding to the dyeing chemicals 10 g/L of anhydrous sodium sulfate and 7 g/L of sodium carbonate, the dyeing process continues for 30 minutes at a temperature of 60° C.; the amount of dyeing chemicals used is 0.5-1% by weight of the weight of the towel.

The desizing and softening processes utilize a solution with 2 g/L high temperature desizing enzyme and continue for 30 minutes at a temperature of 80° C.; after rinsing with water, the greige is soaked in a solution with 3 g/L of JWJ softener at a temperature of 40° C. for 30 minutes. JWJ therein is a softener manufactured by CLARIANT of Switzerland having the function of making the fabric softer and fluffier during the treatment process.

The drying process is done by means of vibrating dryers, such as vibrating dryers manufactured by Sheyang Xinyuan Machinery Manufacturing Co., Ltd.

The dried greige semi-finished product is then sewed to produce low-twist towels.

The present method of manufacturing low-twist towels utilizes pure cotton yarns produced from long-staple cotton as terry warps to manufacture low-twist towel by the processes comprising warping, weaving and greige post treatment, and the terry warp has a yarn twist multiplier of 240-270. The method eliminates the step of removing water-soluble filaments during post treatment, thereby reducing post treatment costs, relieving the pressure on sewage treatment and attaining environmental friendly effects. The resulting products have standing loops and a fluffy and soft texture.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is further elaborated herein by a preferred embodiment. It should be understood that the embodiment employed herein is for the purpose of description and should not be regarded as limiting the scope of the present invention. Besides, it should be understood that upon reading the disclosure as taught by the present invention, those skilled in the art may make any modifications and changes to the present invention but all such equivalents should be resorted to falling within the scope of the present invention.

Embodiment

Low-twist towels are produced from high-quality long staple cotton by the following processes:

Raw cotton treatment process: High-quality long staple cotton is fluffed up and blended by means of a bale plucker and then fed into a cotton opener.

Cotton opening and picking process: The blended long-staple cotton is fluffed up and the impurities are removed therefrom to produce cotton laps or cotton layers of required specification.

Cotton carding process: The processed cotton laps or cotton layers are fed into a carding machine for combing.

Combing process: The card slivers are subject to fine combing so that short staple, impurities and cotton knots are removed therefrom to produce slivers of good quality.

Drawing process: 8 strands are blended together.

Roving process: The card slivers are drawn to be thinner by 7.12 times. The rovings after being twisted are wound onto bobbins to form spools of rovings.

Spinning process: The rovings are drawn out and spinned into spun rovings. The spun rovings are wound onto a bobbin to form a yarn which has a twist multiplier of 240-270.

Warping is done by means of a Benninger sectional warping machine.

Weaving is done by a G6300 Rapier Loom with a warp density of 56 reed, a weft density of 42-45 wefts per 2.54 cm, a loop height of 1.10 cm (10 loops) and a loom speed of 420 revolutions per minute.

The greige is then subject to post treatment processes which comprises:

Desizing process: The greige is soaked in 2 g/L of high temperature desizing enzyme at a temperature of 80° C. for 30 minutes.

Scouring process: Scouring is done by sodium hydroxide, hydrogen peroxide stabilizer and hydrogen peroxide. The scouring solution has a sodium hydroxide concentration of 5±0.5 ml/L, a hydrogen peroxide stabilizer concentration of 0.7±0.05 ml/L, and a hydrogen peroxide concentration of 6.7±0.05 ml/L.

Dyeing process: The dyeing process utilizes Ramazol environmental friendly dyeing chemicals produced by Dystar. After adding to the dyeing chemicals 10 g/L of anhydrous sodium sulfate and 7 g/L of sodium carbonate, the dyeing process continues for 30 minutes at a temperature of 60° C.

Softening process: After adding 3 g/L of JWJ softener, the greige is soaked for 30 minutes at a temperature of 40° C. so that the products are softer. An overflowing dyeing machine may be used.

Drying process: The drying process is done by means of vibrating dryers.

Sewing process: The dried greige semi-finished product is subject to sewing process. 

1. A method for manufacturing low-twist towels, characterized in that pure cotton yarns produced from long-staple cotton are used as terry warps to manufacture low-twist towel by processes comprising warping, weaving and greige post treatment, and the terry warp has a yarn twist_multiplier of 240-270.
 2. The method for manufacturing low-twist towels as in claim 1, characterized in that the pure cotton yarns are produced from the long-staple cotton by the following processes, namely: Cotton opening and picking process wherein raw long-staple cotton are opened and picked to produce cotton laps or cotton layers; Cotton carding process wherein the processed cotton laps or cotton layers are combed to form card slivers; Combing process wherein the card slivers are subject to fine combing; Drawing process wherein 6-8 strands are blended together; Roving process wherein the card slivers are drawn to be thinner by 5-12 times to produce rovings; Spinning process wherein the rovings are drawn out and spinned into spun rovings; Yarn winding process wherein the spun rovings are wound onto a bobbin to form a yarn.
 3. The method for manufacturing low-twist towels as in claim 1, characterized in that the pure cotton yarn produced from the long-staple cotton has a yarn count of 64.8 tex and a twist number of 30 turns per 10 cm.
 4. The method for manufacturing low-twist towels as in claim 1, characterized in that the greige post treatment comprises the processes of desizing, scouring, dyeing, softening and drying.
 5. The method for manufacturing low-twist towels as in claim 4, characterized in that the scouring process uses a scouring solution which has a sodium hydroxide concentration of 5±0.5 ml/L, a hydrogen peroxide stabilizer concentration of 0.7±0.05 ml/L, and a hydrogen peroxide concentration of 6.7±0.05 ml/L.
 6. The method for manufacturing low-twist towels as in claim 4, characterized in that dyeing chemicals used in the dyeing process are in an amount of 0.5-1% by weight of the weight of the towel.
 7. The method for manufacturing low-twist towels as in claim 4, characterized in that the desizing and softening processes utilize a solution with 2 g/L high temperature desizing enzyme and continue for 30 minutes at a temperature of 80° C.; after rinsing with water, the greige is soaked in a solution with 3 g/L of JWJ softener at a temperature of 40° C. for 30 minutes.
 8. The method for manufacturing low-twist towels as in claim 4, characterized in that the drying process is done by means of vibrating dryers. 